Jungheinrich EJC EJC-Z 214 16 Operator Manual

EJC/EJC-Z 14/16 06.
98 -
G
Operating instructions
10004249
01.06
Foreword Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page starts with page 1. The page identification consists of a chapter letter and a page
number. number.
For example: Page B 2 is the second page in chapter B. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model. the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:
f Used before safety instructions which must be observed to avoid danger to

personnel. f Used before safety instructions which must be observed to avoid danger to
personnel.
m Used before notices which must be observed to avoid material damage. m Used before notices which must be observed to avoid material damage.
A Used before notices and explanations. A Used before notices and explanations.
t Used to indicate standard equipment. t Used to indicate standard equipment.
o Used to indicate optional equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating particular features of the truck should therefore be inferred from the present operating
instructions. instructions.
Copyright Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG. Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft
Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - GERMANY 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0 Telephone: +49 (0) 40/6948-0
www.jungheinrich.com www.jungheinrich.com
0108.GB
0108.GB
0108.GB
0108.GB
Table of contents Table of contents
A Correct use and application of the truck A Correct use and application of the truck
B Truck description B Truck description
1 Description of application .................................................................... B 1 1 Description of application .................................................................... B 1

2 Assembly groups ................................................................................. B 2 2 Assembly groups ................................................................................. B 2
3 Technical data ..................................................................................... B 3 3 Technical data ..................................................................................... B 3
3.1 Performance data EJC 14/16 / EJC-Z 14/16 ....................................... B 3 3.1 Performance data EJC 14/16 / EJC-Z 14/16 ....................................... B 3
3.2 Dimensions EJC 14/16 ........................................................................ B 3 3.2 Dimensions EJC 14/16 ........................................................................ B 3
3.3 Dimensions EJC-Z 14/16 .................................................................... B 4 3.3 Dimensions EJC-Z 14/16 .................................................................... B 4
3.4 EN standards ...................................................................................... B 6 3.4 EN standards ...................................................................................... B 6
3.5 Conditions for application .................................................................... B 6 3.5 Conditions for application .................................................................... B 6
4 Location of instruction labels and identification labels ........................ B 7 4 Location of instruction labels and identification labels ........................ B 7
4.1 Truck identification label ...................................................................... B 8 4.1 Truck identification label ...................................................................... B 8
4.2 Load capacity ...................................................................................... B 8 4.2 Load capacity ...................................................................................... B 8
4.3 Load capacity, wheel-arm lifting device .............................................. B 9 4.3 Load capacity, wheel-arm lifting device .............................................. B 9
4.4 Label/Order/Inventory/Service No. ...................................................... B 9 4.4 Label/Order/Inventory/Service No. ...................................................... B 9
C Transportation and commissioning C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1 1 Transportation by crane ...................................................................... C 1

2 First commissioning ............................................................................ C 2 2 First commissioning ............................................................................ C 2
3 Moving the truck without own drive ..................................................... C 3 3 Moving the truck without own drive ..................................................... C 3
D Battery - Servicing, recharging, replacement D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1 1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2 2 Battery types ....................................................................................... D 2
3 Open battery hood .............................................................................. D 2 3 Open battery hood .............................................................................. D 2
4 Charging the battery ............................................................................ D 3 4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3 4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4 4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7 5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards 5.1 Remove battery by lifting it upwards
(truck without wheel-arm lifting device) ............................................... D 7 (truck without wheel-arm lifting device) ............................................... D 7
5.2 Remove battery by lifting it upwards 5.2 Remove battery by lifting it upwards
(truck with wheel-arm lifting device) .................................................... D 8 (truck with wheel-arm lifting device) .................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9 5.3 Lateral battery change (o) .................................................................. D 9
6 Combined instrument .......................................................................... D 10 6 Combined instrument .......................................................................... D 10
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I1 I1
E Operation E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1 1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2 2 Description of controls and indicating instruments .............................. E 2
3 Putting vehicle in operation ................................................................. E 4 3 Putting vehicle in operation ................................................................. E 4
4 Operation of the fork lift truck .............................................................. E 5 4 Operation of the fork lift truck .............................................................. E 5
4.1 Safety regulations applicable when operating the truck ...................... E 5 4.1 Safety regulations applicable when operating the truck ...................... E 5
4.2 Driving, steering, braking .................................................................... E 6 4.2 Driving, steering, braking .................................................................... E 6
4.3 Picking up or lowering load units ......................................................... E 9 4.3 Picking up or lowering load units ......................................................... E 9
4.4 Safe parking of the truck ..................................................................... E 11 4.4 Safe parking of the truck ..................................................................... E 11
4.5 Fault location ....................................................................................... E 11 4.5 Fault location ....................................................................................... E 11
F Maintenance of the fork lift truck F Maintenance of the fork lift truck
1 Operational safety and environmental protection .................................F 1 1 Operational safety and environmental protection .................................F 1
2 Safety regulations applicable to truck maintenance .............................F 1 2 Safety regulations applicable to truck maintenance .............................F 1
3 Servicing and inspection ......................................................................F 3 3 Servicing and inspection ......................................................................F 3
4 Maintenance checklist ..........................................................................F 4 4 Maintenance checklist ..........................................................................F 4
5 Lubrication schedule ...........................................................................F 6 5 Lubrication schedule ...........................................................................F 6
5.1 Fuels, coolants and lubricants ..............................................................F 7 5.1 Fuels, coolants and lubricants ..............................................................F 7
6 Notes on maintenance .........................................................................F 8 6 Notes on maintenance .........................................................................F 8
6.1 Preparation of the truck for servicing and maintenance operation .......F 8 6.1 Preparation of the truck for servicing and maintenance operation .......F 8
6.2 Open the battery hood .........................................................................F 8 6.2 Open the battery hood .........................................................................F 8
6.3 Open the front hood .............................................................................F 8 6.3 Open the front hood .............................................................................F 8
6.4 Check hydraulic oil level .......................................................................F 9 6.4 Check hydraulic oil level .......................................................................F 9
6.5 Check the transmission oil level ...........................................................F 9 6.5 Check the transmission oil level ...........................................................F 9
6.6 Exchanging the coarse sieve ...............................................................F 9 6.6 Exchanging the coarse sieve ...............................................................F 9
6.7 Checking the electric fuses ..................................................................F 10 6.7 Checking the electric fuses ..................................................................F 10
6.8 Recommissioning the truck ..................................................................F 11 6.8 Recommissioning the truck ..................................................................F 11
7 Decommissioning the fork lift truck ......................................................F 11 7 Decommissioning the fork lift truck ......................................................F 11
7.1 Operations to be performed prior to decommissioning ........................F 11 7.1 Operations to be performed prior to decommissioning ........................F 11
7.2 Measures to be taken during decommissioning ...................................F 11 7.2 Measures to be taken during decommissioning ...................................F 11
7.3 Recommissioning the truck ..................................................................F 12 7.3 Recommissioning the truck ..................................................................F 12
8 Safety checks to be performed at regular 8 Safety checks to be performed at regular
intervals and following any untoward incidents intervals and following any untoward incidents
(D: Accident prevention check according to VBG 36) ......................F 12 (D: Accident prevention check according to VBG 36) ......................F 12
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I2 I2
A Correct use and application of the truck A Correct use and application of the truck
A The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these ope-
A The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these ope-
rating instructions and must always be heeded. National regulations are fully applica- rating instructions and must always be heeded. National regulations are fully applica-
ble. ble.
The fork lift truck described in these operating instructions is a truck that is suitable The fork lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads. for lifting and transporting loads.
It must be used, operated and maintained according to the information in these ope- It must be used, operated and maintained according to the information in these ope-
rating instructions. Any other uses are outside the design envelope and can lead to rating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis- caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork lift truck must not be operated in spaces subject to fire shown on the truck. The fork lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail. vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork lift truck himself, or on fined as any natural or legal person who either uses the fork lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-
red the person, who, in accordance with existing contractual agreements between the red the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork lift truck, is charged with the observance of the opera- owner and the user of the fork lift truck, is charged with the observance of the opera-
ting duties. ting duties.
The user must ensure that the truck is not abused and only used within its design li- The user must ensure that the truck is not abused and only used within its design li-
mits and that all danger to life and limb of the operator, or third parties, is avoided. In mits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte- and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions. the truck have read and understood these operating instructions.
m If these operating instructions are not observed the warranty becomes void. The same app-
lies if improper works are carried out at the device by the customer and/or third parties without
m If these operating instructions are not observed the warranty becomes void. The same app-
lies if improper works are carried out at the device by the customer and/or third parties without
permission of our Customer Service. permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ- will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained. local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary. by the manufacturer unnecessary.
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A1 A1
A2
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A2
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B Truck description B Truck description
1 Description of application 1 Description of application
The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel. The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel.
It is conceived for lifting and transporting palleted goods on level ground. Either open- It is conceived for lifting and transporting palleted goods on level ground. Either open-
ground pallets or trolleys can be picked up. ground pallets or trolleys can be picked up.
A wheel-arm lifting device is available as an option, extending the ground clearance A wheel-arm lifting device is available as an option, extending the ground clearance
during transports on uneven ground. during transports on uneven ground.
The nominal load capacity can be found on the identification label. The nominal load capacity can be found on the identification label.
The load capacity in relation to lifting height and load centre distance is specified on The load capacity in relation to lifting height and load centre distance is specified on
the load capacity label. the load capacity label.
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B1 B1
2 Assembly groups 2 Assembly groups
7 7
4 8 4 8
5 5 5 5
6 9 6 9
3 3
10 10
2 2
11 11
1 1
12 12
16 16
13 13
15 15
14 14
Pos. EJC EJC-Z Description Pos. EJC EJC-Z Description

14/16 14/16 14/16 14/16
1 t t Key switch 1 t t Key switch
2 o o Combined instrument 2 o o Combined instrument
(battery discharge monitor and operating hour meter) (battery discharge monitor and operating hour meter)
3 t t Control shaft with control shaft head 3 t t Control shaft with control shaft head
4 t t “Shunt driving” button 4 t t “Shunt driving” button
5 t t Driving regulator 5 t t Driving regulator
6 t t Collision-guard button 6 t t Collision-guard button
7 t t Hoist frame 7 t t Hoist frame
8 t t Protective pane 8 t t Protective pane
9 t t Battery hood 9 t t Battery hood
10 t t Master switch (emergency stop) 10 t t Master switch (emergency stop)
11 o - Battery charger 11 o - Battery charger
12 t t Lifting device 12 t t Lifting device
13 t t Front hood 13 t t Front hood
14 t t Supporting wheel 14 t t Supporting wheel
15 t t Drive wheel 15 t t Drive wheel
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16 o o Document case 16 o o Document case
B2 B2
3 Technical data 3 Technical data
A Specification of technical data according to VDI 2198. Technical modifications and

supplements reserved.
A Specification of technical data according to VDI 2198. Technical modifications and
supplements reserved.
3.1 Performance data EJC 14/16 / EJC-Z 14/16 3.1 Performance data EJC 14/16 / EJC-Z 14/16
Description EJC 14 EJC 16 Description EJC 14 EJC 16

EJC-Z 14 EJC-Z 16 EJC-Z 14 EJC-Z 16
Q Nominal load capacity 1400 1600 kg Q Nominal load capacity 1400 1600 kg
C Load centre distance at standard fork length 600 600 mm C Load centre distance at standard fork length 600 600 mm
Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/h Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/h
Lifting speed with / without load 15 / 23 14 / 23 cm/s Lifting speed with / without load 15 / 23 14 / 23 cm/s
Lowering speed with / without load 40 / 40 40 / 40 cm/s Lowering speed with / without load 40 / 40 40 / 40 cm/s
Max. hill-climbing ability with / without load 8 / 16 7 / 16 % Max. hill-climbing ability with / without load 8 / 16 7 / 16 %
3.2 Dimensions EJC 14/16 3.2 Dimensions EJC 14/16
Description Version1) EJC 14 EJC 16 Description Version1) EJC 14 EJC 16

Overall height (depending on Overall height (depending on
h1 2) 1700 - 2600 1700 - 2600 mm h1 2) 1700 - 2600 1700 - 2600 mm
mast) mast)
h2 Free lifting capacity 3) 100 100 mm h2 Free lifting capacity 3) 100 100 mm
short 2500 - 4300 2400 - 4200 short 2500 - 4300 2400 - 4200
h3 Lifting height (depending on mast) mm h3 Lifting height (depending on mast) mm
long 2500 - 5350 2400 - 5250 long 2500 - 5350 2400 - 5250
height with mast protruded short 2981 - 4781 2931 - 4731 height with mast protruded short 2981 - 4781 2931 - 4731
h4 7) mm h4 7) mm
(depending on mast type) long 2981 - 5831 2931 - 5781 (depending on mast type) long 2981 - 5831 2931 - 5781
Free lifting capacity Free lifting capacity
4) 8) 4) 8)
h5 (double-lifting device) 1219 - 2119 1169 - 2069 mm h5 (double-lifting device) 1219 - 2119 1169 - 2069 mm
(depending on mast type) (depending on mast type)
h13 Fork lowered 90 90 mm h13 Fork lowered 90 90 mm
short 1217 1217 short 1217 1217
y Wheel base mm y Wheel base mm
long 1357 1357 long 1357 1357
6) short 1836 1836 6) short 1836 1836
l1 Truck length (= l2 + l) mm l1 Truck length (= l2 + l) mm
long 1976 1976 long 1976 1976
5) 6) short 686 686 5) 6) short 686 686
l2 Length of front section mm l2 Length of front section mm
long 826 826 long 826 826
B Truck width 800 800 mm B Truck width 800 800 mm
b5 Overall distance of fork 560 560 mm b5 Overall distance of fork 560 560 mm
m2 Ground clearance 30 30 mm m2 Ground clearance 30 30 mm
Working corridor width 5) 6) short 2140 2140 Working corridor width 5) 6) short 2140 2140
Ast mm Ast mm
800 x 1200 longitudinal long 2278 2278 800 x 1200 longitudinal long 2278 2278
Working corridor width 5) 6) Working corridor width 5) 6)
short 2277 2277 short 2277 2277
Ast 800 x 1200 longitudinal mm Ast 800 x 1200 longitudinal mm
long 2416 2416 long 2416 2416
(according to VDI) (according to VDI)
Turning circle for shunt driving short 1428 1428 Turning circle for shunt driving short 1428 1428
Wa mm Wa mm
(raised control shaft) long 1567 1567 (raised control shaft) long 1567 1567
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B3 B3
3.3 Dimensions EJC-Z 14/16 3.3 Dimensions EJC-Z 14/16
Description Version1) EJC-Z 14 EJC-Z 16 Description Version1) EJC-Z 14 EJC-Z 16

2) 2)
h1 Overall height (depending on mast) 1700 - 2600 1700 - 2600 mm h1 Overall height (depending on mast) 1700 - 2600 1700 - 2600 mm
3) 3)
h2 Free lifting capacity 100 100 mm h2 Free lifting capacity 100 100 mm
h3 Lifting height (depending on mast) short 2500 - 4300 2400 - 4200 mm h3 Lifting height (depending on mast) short 2500 - 4300 2400 - 4200 mm
long 2500 - 5350 2400 - 5250 long 2500 - 5350 2400 - 5250
h4 height with mast protruded 7) short 2981 - 4781 2931 - 4731 mm h4 height with mast protruded 7) short 2981 - 4781 2931 - 4731 mm
(depending on mast type) long 2981 - 5831 2931 - 5781 (depending on mast type) long 2981 - 5831 2931 - 5781
h5 Free lifting capacity (double-lifting de- 1219 - 2119 1169 - 2069 mm h5 Free lifting capacity (double-lifting de- 1219 - 2119 1169 - 2069 mm
vice) (depending on mast type) 4) 8) vice) (depending on mast type) 4) 8)
h13 Fork lowered 90 90 mm h13 Fork lowered 90 90 mm
y Wheel position (lowered/lifted) short 1457/1397 1457/1397 mm y Wheel position (lowered/lifted) short 1457/1397 1457/1397 mm
long 1597/1537 1597/1537 long 1597/1537 1597/1537
6) 6)
l1 Truck length (= l2 + l) short 1868 1868 mm l1 Truck length (= l2 + l) short 1868 1868 mm
long 2008 2008 long 2008 2008
5) 6) 5) 6)
l2 Length of front section short 718 718 mm l2 Length of front section short 718 718 mm
long 858 858 long 858 858
B Truck width 830 830 mm B Truck width 830 830 mm
b5 Overall distance of fork 560 560 mm b5 Overall distance of fork 560 560 mm
9) 9)
m2 Ground clearance 20 20 mm m2 Ground clearance 20 20 mm
5) 6) 5) 6)
Ast Working corridor width short 2171 2171 mm Ast Working corridor width short 2171 2171 mm
800 x 1200 longitudinal long 2310 2310 800 x 1200 longitudinal long 2310 2310
5) 6) 5) 6)
Ast Working corridor width short 2348 2348 mm Ast Working corridor width short 2348 2348 mm
800 x 1200 longitudinal (according to long 2487 2487 800 x 1200 longitudinal (according to long 2487 2487
VDI) VDI)
Wa Turning circle for shunt driving short 1668/1608 1668/1608 mm Wa Turning circle for shunt driving short 1668/1608 1668/1608 mm
(raised control shaft) long 1807/1747 1807/1747 (raised control shaft) long 1807/1747 1807/1747
Wheel arms lowered/raised Wheel arms lowered/raised
h31 Lifting height of wheel-arm 122 122 mm h31 Lifting height of wheel-arm 122 122 mm
1) 1)
“short/long” version refers to the length of the battery compartment (see chap. D) “short/long” version refers to the length of the battery compartment (see chap. D)
2) for ZT hoist frame with 100 mm free lifting capacity (h2) : (h1) = + 50 mm 2) for ZT hoist frame with 100 mm free lifting capacity (h2) : (h1) = + 50 mm
3) onyl telescope hoist frame (ZT) 3) onyl telescope hoist frame (ZT)
4) 4)
only ZZ and DZ hoist frame only ZZ and DZ hoist frame
5) with load guard: (l2) = + 15 mm 5) with load guard: (l2) = + 15 mm
6) 6)
with DZ hoist frame: (l2) = + 38 mm (EJC 14) + 43 mm (EJC 16) with DZ hoist frame: (l2) = + 38 mm (EJC 14) + 43 mm (EJC 16)
7) with LSG + 610 mm (EJC 14) + 560 mm (EJC/EJC(-Z)16) 7) with LSG + 610 mm (EJC 14) + 560 mm (EJC/EJC(-Z)16)
8) 8)
with LSG - 610 mm (EJC 14) - 560 mm (EJC 16) with LSG - 610 mm (EJC 14) - 560 mm (EJC 16)
9) 9)
Wheel-arm lifting height with lowered wheel arm Wheel-arm lifting height with lowered wheel arm
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B4 B4
h4 h4
h3 h3
h1 h1
h5 l h5 l
c c
h2 h31 h2 h31
Q Q
m2 m2
l2 l2
h13 h13
y y
l1 l1
Ast Ast
b5 B b5 B
W W
a a
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B5 B5
3.4 EN standards 3.4 EN standards
Continuous sound level: 65 dB(A) Continuous sound level: 65 dB(A)

according to prEN 12053 as stipulated in ISO 4871. according to prEN 12053 as stipulated in ISO 4871.
A The continuous sound level is a value averaged according to standard regulations,

taking the sound pressure level into account when driving, lifting and idling. The
A The continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear. sound pressure level is measured at the ear.
Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit The manufacturer confirms compliance with the limit
values for electromagnetic emission and interference values for electromagnetic emission and interference
immunity as well as testing of static electricity dischar- immunity as well as testing of static electricity dischar-
ge according to prEN 12895 and the references to ge according to prEN 12895 and the references to
other standards contained therein. other standards contained therein.
A Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
A Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.5 Conditions for application 3.5 Conditions for application
Ambient temperature: Ambient temperature:
- during operation 5 °C to 40 °C - during operation 5 °C to 40 °C
A Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5 °C or in cold stores respectively with extreme
A Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5 °C or in cold stores respectively with extreme
temperatures or humidity changes. temperatures or humidity changes.
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B6 B6
4 Location of instruction labels and identification labels 4 Location of instruction labels and identification labels
Xxx
Xxxx
Xxxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
21 22 Xxx
Xxxx
Xxxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
21 22
Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg
Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx

Xxxxxxxxxx V Xxxxxxxxxxxxxxxxx kW xxxxxxxx kg Xxxxxxxxxx V Xxxxxxxxxxxxxxxxx kW xxxxxxxx kg
Xxxxxxx Xxxxxxx
Xxxxxx Xxxxxx
Xxxxx Xxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxx

Xxxx Xxxxxxxxxxxxxxxxxx Xxxx Xxxxxxxxxxxxxxxxxx
20 20
23 23
19 19
18 24 18 24
17 17
25 25
21a 26 21a 26
Item Description Item Description

17 Load capacity wheel-arm lifting device 17 Load capacity wheel-arm lifting device
18 Load capacity 18 Load capacity
19 Prohibition sign “Do not transport other persons” 19 Prohibition sign “Do not transport other persons”
20 Truck identification label 20 Truck identification label
21 Limit-stop for crane loading (21a only EJC-Z) 21 Limit-stop for crane loading (21a only EJC-Z)
22 Prohibition sign “Keep away from under the load lifting device” 22 Prohibition sign “Keep away from under the load lifting device”
23 Prohibition sign “Do not put your hands through the hoist frame” 23 Prohibition sign “Do not put your hands through the hoist frame”
24 UVV control label 24 UVV control label
25 Identification label, battery 25 Identification label, battery
26 Warning sign “Caution: Low-voltage electronics” 26 Warning sign “Caution: Low-voltage electronics”
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B7 B7
4.1 Truck identification label 4.1 Truck identification label
39 39
27 27
28 38 28 38
29 37 29 37
30 30
36 36
31 31
35 35
32 32
33 34 33 34
Item Designation Item Designation Item Designation Item Designation

27 Type 34 Drive power in kW 27 Type 34 Drive power in kW
28 Serial No. 35 Customer no. 28 Serial No. 35 Customer no.
29 Rated capacity in kg 36 Min./max. battery weight in kg 29 Rated capacity in kg 36 Min./max. battery weight in kg
30 Battery: Voltage V 37 Dead weight without battery in kg 30 Battery: Voltage V 37 Dead weight without battery in kg
Ampere hours Ah Ampere hours Ah
31 Manufacturer 38 Year of manufacture 31 Manufacturer 38 Year of manufacture
32 Order no. 39 Manufacturer logo 32 Order no. 39 Manufacturer logo
33 Load centre distance in mm 33 Load centre distance in mm
A In the event of queries relating to the truck or spare part orders, please state the serial
no. (28) of the truck.
A In the event of queries relating to the truck or spare part orders, please state the serial
no. (28) of the truck.
4.2 Load capacity 4.2 Load capacity
f The label (18) includes a table indicating

the loading capacity
18 f The label (18) includes a table indicating
the loading capacity
18
(Q in kg) in relation to the load centre di- (Q in kg) in relation to the load centre di-
stance (D in mm) and the lifting height (H stance (D in mm) and the lifting height (H
in mm). in mm).
The arrow-shaped markings on the inner mast (40) and outer mast 40 41 The arrow-shaped markings on the inner mast (40) and outer mast 40 41
(41) show the driver when he has reached the lifting height limits that (41) show the driver when he has reached the lifting height limits that
is defined on the load capacity label (18). is defined on the load capacity label (18).
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B8 B8
4.3 Load capacity, wheel-arm lifting device 4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (17) indicating Trucks with a wheel-arm lifting device are provided with an extra label (17) indicating
the permissible assignment to wheel-arm lifting device and main lifting device. the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No. 4.4 Label/Order/Inventory/Service No.

42 42
43 43
44 44
Item Description Item Description

42 Order no. 42 Order no.
43 Inventory No. 43 Inventory No.
44 Full Service No. 44 Full Service No.
A This label contains the Full Service No. and is only handed out when a service con-
tract is being concluded.
A This label contains the Full Service No. and is only handed out when a service con-
tract is being concluded.
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B9 B9
B 10
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B 10
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C Transportation and commissioning C Transportation and commissioning
1 Transportation by crane 1 Transportation by crane
f Only use lifting equipment with sufficient bearing capacity (loading weight see identi-
fication label on truck).
f Only use lifting equipment with sufficient bearing capacity (loading weight see identi-
fication label on truck).
If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful
not to protrude the lifting cylinders while the truck is being lifted. If the device is com- not to protrude the lifting cylinders while the truck is being lifted. If the device is com-
pletely protruded, there is the risk that the cylinder protection is being released due pletely protruded, there is the risk that the cylinder protection is being released due
to overloading. to overloading.
A A hoisting point (1) is provided at the hoist frame for loading the truck with the help of
hoisting gear.
A A hoisting point (1) is provided at the hoist frame for loading the truck with the help of
hoisting gear.
Trucks that are provided a with wheel-arm lifting device, have two more hoisting Trucks that are provided a with wheel-arm lifting device, have two more hoisting
points (2) for loading. points (2) for loading.
– Park the truck and render it safe – Park the truck and render it safe
(refer to chapter E). (refer to chapter E).
1 1
– Attach the hoisting gear to the stop (1) – Attach the hoisting gear to the stop (1)
on the hoisting mast. on the hoisting mast.
– In case of trucks that are provided with – In case of trucks that are provided with
a wheel-arm lifting device, the hoisting a wheel-arm lifting device, the hoisting
gear can also be attached to the stops gear can also be attached to the stops
(2) on the vehicle chassis. (2) on the vehicle chassis.
m Secure the hoisting gear to the hoisting

points ensuring that the hoisting gear will
m Secure the hoisting gear to the hoisting
points ensuring that the hoisting gear will
not slip! The hoisting gear must be atta- not slip! The hoisting gear must be atta-
ched in such a way that it does touch any ched in such a way that it does touch any
add-on parts while the truck is being lif- add-on parts while the truck is being lif-
ted. ted.
Trucks with wheel-arm lifting device Trucks with wheel-arm lifting device
must hang horizontally or slightly incli- 2 must hang horizontally or slightly incli- 2
ned in the direction of the lifting device. ned in the direction of the lifting device.
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C1 C1
2 First commissioning 2 First commissioning
m The truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (towing cable) must be less
m The truck must only be operated on battery current. Rectified alternate current will da-
mage the electronics. Cables connected to the battery (towing cable) must be less
than 6 meters in length. than 6 meters in length.
f It is prohibited to hoist loads when the truck is operated via a towing cable with an
external battery.
f It is prohibited to hoist loads when the truck is operated via a towing cable with an
external battery.
In order to prepare the truck for work following delivery or transportation, the following In order to prepare the truck for work following delivery or transportation, the following
operations must be performed: operations must be performed:
– Check whether the equipment is complete and in perfect condition. – Check whether the equipment is complete and in perfect condition.
– If required, mount the battery, make sure not to damage the battery cable – If required, mount the battery, make sure not to damage the battery cable
(see chapter D). (see chapter D).
A At trucks with an optionally built-in battery charger, adjust the characteristics (loading
cam) (see chapter D).
A At trucks with an optionally built-in battery charger, adjust the characteristics (loading
cam) (see chapter D).
– Load the battery (see chapter D). – Load the battery (see chapter D).
– If required, check whether the settings of the combined instrument correspond to – If required, check whether the settings of the combined instrument correspond to
the battery (see chapter D). the battery (see chapter D).
– Commission the truck as prescribed – Commission the truck as prescribed
(see chapter E). (see chapter E).
A If the truck is parked for longer periods, the running surfaces of the wheels may be
flattened. However, this flattening will disappear quickly when the truck is being
A If the truck is parked for longer periods, the running surfaces of the wheels may be
flattened. However, this flattening will disappear quickly when the truck is being
driven. driven.
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C2 C2
3 Moving the truck without own drive 3 Moving the truck without own drive
f This type of operation is prohibited on slopes and inclinations.

f This type of operation is prohibited on slopes and inclinations.
If the truck must still be moved after a fault has occurred, proceed as follows: If the truck must still be moved after a fault has occurred, proceed as follows:
– Set master switch to “OFF” position. – Set master switch to “OFF” position.
– Set key switch to “0” position and re- – Set key switch to “0” position and re-
move the key. move the key.
– Secure the truck against rolling away. – Secure the truck against rolling away.
– Open and remove front hood – Open and remove front hood
(see chapter F). (see chapter F).
– Turn the screws (3) anticlockwise until – Turn the screws (3) anticlockwise until
you reach the limit stop. you reach the limit stop.
The solenoid brake is triggered. The The solenoid brake is triggered. The
truck can now no longer be moved. truck can now no longer be moved.
f If you reached the target location, reset

the brake system to its original condition! The truck must not be parked with released
f If you reached the target location, reset
the brake system to its original condition! The truck must not be parked with released
brake! brake!
– Return the screws (3) anticlockwise until they touch the limit stop. – Return the screws (3) anticlockwise until they touch the limit stop.
The original brake condition is restored. The original brake condition is restored.
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C3 C3
C4
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C4
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D Battery - Servicing, recharging, replace- D Battery - Servicing, recharging, replace-
ment ment
1 Safety regulations governing the handling of lead-acid batteries 1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E). undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual, formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations. station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery re- be present or stored within a distance of 2 meters of the truck parked for battery re-
charging. The location must be well ventilated and fire fighting equipment must be charging. The location must be well ventilated and fire fighting equipment must be
kept ready. kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non- securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat. skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu- tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded. facturer’s specifications for the disposal must be heeded.
m Before closing the battery hood, make sure that the battery cable cannot be dama-
ged.
m Before closing the battery hood, make sure that the battery cable cannot be dama-
ged.
f Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
f Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid. physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con- the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized. tact with battery acid. Spilled battery acid must be immediately neutralized.
m Only batteries with closed tray may be used.

m Only batteries with closed tray may be used.
f Battery weight and dimensions have considerable influence on operational safety of

the truck. Changing the battery equipment is not permitted without prior approval by
f Battery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer. the manufacturer.
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D1 D1
2 Battery types 2 Battery types
The vehicle is equipped with different battery types depending on the type. The vehicle is equipped with different battery types depending on the type.
The battery weights are specified on identification label of the battery. The battery weights are specified on identification label of the battery.
m When changing / assembling the battery, make sure that it is properly fixed in the bat-
tery compartment the truck.
m When changing / assembling the battery, make sure that it is properly fixed in the bat-
tery compartment the truck.
The following table shows the standard battery combinations and battery capacities: The following table shows the standard battery combinations and battery capacities:
Truck type 24V - Pz... - battery Truck type 24V - Pz... - battery
EJC 14 2 PzB 126 Ah EJC 14 2 PzB 126 Ah
EJC 14 2 PzB 150 Ah EJC 14 2 PzB 150 Ah
EJC /-Z 14 / 16 2 PzB 180 Ah EJC /-Z 14 / 16 2 PzB 180 Ah
EJC /-Z 14 / 16 3 PzS L 270 Ah EJC /-Z 14 / 16 3 PzS L 270 Ah
EJC /-Z 14 / 16 3 PzS L 330 Ah EJC /-Z 14 / 16 3 PzS L 330 Ah
Depending on the battery type, also high-performance or maintenance-free batteries Depending on the battery type, also high-performance or maintenance-free batteries
can be used. can be used.
3 Open battery hood 3 Open battery hood
– Park the truck and render it safe (refer to chapter E). – Park the truck and render it safe (refer to chapter E).
– Set master switch (2) to “OFF” position. – Set master switch (2) to “OFF” position.
– Open the battery hood (1). – Open the battery hood (1).
f The battery hood (1) is held in place by its own weight.

f The battery hood (1) is held in place by its own weight.
1 1
2 2
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D2 D2
4 Charging the battery 4 Charging the battery
As default, the truck is to be loaded with a stationary battery charger. The truck wit- As default, the truck is to be loaded with a stationary battery charger. The truck wit-
hout wheel-arm lifting device can optionally be supplied with an integrated battery hout wheel-arm lifting device can optionally be supplied with an integrated battery
charger. charger.
m For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated
environment.
m For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated
environment.
4.1 Charging the battery with stationary battery charger 4.1 Charging the battery with stationary battery charger
m Connection / disconnecting battery connector and socket as well as pressing the ma-
ster switch (2) may only be performed with truck and battery charger being switched
m Connection / disconnecting battery connector and socket as well as pressing the ma-
ster switch (2) may only be performed with truck and battery charger being switched
off. off.
– Expose the battery (refer to section 3). – Expose the battery (refer to section 3).
f During the recharging operation the tops of the battery cells must be exposed to en-
sure adequate ventilation. Metal objects must not be placed on the battery. Prior to
starting the recharging operation, check all cable connections and plugged connec- starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage. tions for visible damage.
The safety instructions provided by the battery supplier and battery charger supplier The safety instructions provided by the battery supplier and battery charger supplier
must be strictly observed. must be strictly observed.
– Pull battery connector (3) from the plug and socket connection of the truck. – Pull battery connector (3) from the plug and socket connection of the truck.
– Remove insulation mat from battery, if necessary. – Remove insulation mat from battery, if necessary.
– Connect the charging cable (4) of the battery recharging station with the battery – Connect the charging cable (4) of the battery recharging station with the battery
connector (3) and switch on the battery charger. connector (3) and switch on the battery charger.
m Recharge the battery observing the instructions provided by the battery supplier and
by the battery charger supplier.
m Recharge the battery observing the instructions provided by the battery supplier and
by the battery charger supplier.
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D3 D3
4.2 Recharging the battery with integrated battery charger (o) 4.2 Recharging the battery with integrated battery charger (o)
f The battery charger must not be opened. If it is damaged, it has to be exchanged.

f The battery charger must not be opened. If it is damaged, it has to be exchanged.
A Due to safety reasons, intermediate positions are available between the regulation
positions “1” to “6” of the switch (7).
A Due to safety reasons, intermediate positions are available between the regulation
positions “1” to “6” of the switch (7).
If the truck is delivered without battery, an intermediate position is pre-selected as de- If the truck is delivered without battery, an intermediate position is pre-selected as de-
fault. The red light-emitting diode (5) flashes - the battery cannot be recharged. fault. The red light-emitting diode (5) flashes - the battery cannot be recharged.
7 7
6 5 6 5
Select charging curve in the integrated battery charger Select charging curve in the integrated battery charger
Use switch (7) at the battery charger to adjust the charging curves to the appropriate Use switch (7) at the battery charger to adjust the charging curves to the appropriate
battery according to the following table. battery according to the following table.
m The power plug must be pulled before the corresponding charging curve is to be ad-
justed!
m The power plug must be pulled before the corresponding charging curve is to be ad-
justed!
Provided that a battery is connected, a new setting can be acknowledged via the Provided that a battery is connected, a new setting can be acknowledged via the
LEDs (cf., indicator) which will then be immediately effective. LEDs (cf., indicator) which will then be immediately effective.
Position of switch (7) selected charging curves (characteristics) Position of switch (7) selected charging curves (characteristics)
1 Wet batteries: 100 - 300 Ah 1 Wet batteries: 100 - 300 Ah
2 Maintenance-free: 100 - 140 Ah 2 Maintenance-free: 100 - 140 Ah
5 Free 5 Free
6 Free 6 Free
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D4 D4
Adjusting the charging curve Adjusting the charging curve
The charging curve can be adjusted by performing the following steps: The charging curve can be adjusted by performing the following steps:
Connect the battery This permits to use the battery Connect the battery This permits to use the battery
charger as an adjustment aid charger as an adjustment aid
Turn the adjustment switch to The red LED flashes fast no valid Turn the adjustment switch to The red LED flashes fast no valid
the right (i.e. clockwise) until it charging curve sel- the right (i.e. clockwise) until it charging curve sel-
touches the limit stop. ected touches the limit stop. ected
Turn the adjustment switch to After 3 seconds the green LED charging curve 1 Turn the adjustment switch to After 3 seconds the green LED charging curve 1
the left flashes only once selected the left flashes only once selected
(i.e. anticlockwise) until it tou- (i.e. anticlockwise) until it tou-
ches the limit stop. ches the limit stop.
Select the desired charging The red LED starts to flash in Select the desired charging The red LED starts to flash in
curve by turning the adjust- the intermediate positions. curve by turning the adjust- the intermediate positions.
ment switch to the right If a valid charging curve is sel- ment switch to the right If a valid charging curve is sel-
ected, the green LED starts to ected, the green LED starts to
flash in the relevant switch po- flash in the relevant switch po-
sition. sition.
Starting the recharging process with integrated battery charger Starting the recharging process with integrated battery charger
starting the recharging operation, check all cable connections and plugged connec- starting the recharging operation, check all cable connections and plugged connec-
tions for visible damage. The safety instructions provided by the battery supplier and tions for visible damage. The safety instructions provided by the battery supplier and
battery charger supplier must be strictly observed. battery charger supplier must be strictly observed.
Mains supply Mains supply

Line voltage: 230 V (+10/-15%) Line voltage: 230 V (+10/-15%)
Line frequency: 50 Hz / 60 Hz Line frequency: 50 Hz / 60 Hz
The power plug (8) of the battery charger can be found in the battery compartment. The power plug (8) of the battery charger can be found in the battery compartment.
8 8
– Remove insulation mat from battery, if necessary. – Remove insulation mat from battery, if necessary.
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– Pull out master switch (2) (position “ON”). – Pull out master switch (2) (position “ON”).
– Connect power plug (8) with a power socket. – Connect power plug (8) with a power socket.
D5 D5
A The master switch (2) may only be operated with truck and battery charger being swit-
ched off.
A The master switch (2) may only be operated with truck and battery charger being swit-
ched off.
The flashing LED indicates the charging status and/or a fault (flashing codes see ta- The flashing LED indicates the charging status and/or a fault (flashing codes see ta-
ble “LED display”). ble “LED display”).
A If the power plug (8) is connected to the mains, all electric functions of the truck are
interrupted (electric driving lock). No operation of the truck is possible.
A If the power plug (8) is connected to the mains, all electric functions of the truck are
interrupted (electric driving lock). No operation of the truck is possible.
– Pull plug (8) from the power socket and place it in the battery compartment. – Pull plug (8) from the power socket and place it in the battery compartment.
A The recharge procedure is automatically continued after a power failure.

The recharge procedure can be interrupted by pulling the power plug and can be con-
A The recharge procedure is automatically continued after a power failure.
The recharge procedure can be interrupted by pulling the power plug and can be con-
tinued in steps. tinued in steps.
f The mains cable must not be damaged.

Before commissioning the truck, the battery hood must be properly closed.
f The mains cable must not be damaged.
Charging times Charging times
The time required for recharging depends on the capacity of the battery. The time required for recharging depends on the capacity of the battery.
LED display LED display
Green LED (6) Red LED (5) Indication Green LED (6) Red LED (5) Indication
(charging (fault) (charging (fault)
status) status)
is lit --- Recharge procedure is finished; battery is full. is lit --- Recharge procedure is finished; battery is full.
(charging break, (charging break,
fill-up charge or equalization charge) fill-up charge or equalization charge)
flashes slowly --- Charging process flashes slowly --- Charging process
flashes fast --- Indicates the start of a recharge procedure or that a flashes fast --- Indicates the start of a recharge procedure or that a
new charging curve was adjusted. The number of new charging curve was adjusted. The number of
the flashing pulses corresponds to the adjusted the flashing pulses corresponds to the adjusted
charging curve. charging curve.
--- is lit Excess temperature. Recharge process is interrup- --- is lit Excess temperature. Recharge process is interrup-
ted. ted.
--- flashes slowly Safety charging interval exceeded. Recharge pro- --- flashes slowly Safety charging interval exceeded. Recharge pro-
cess is interrupted. Disconnection from the mains is cess is interrupted. Disconnection from the mains is
required required
for restarting the charging process. for restarting the charging process.
--- flashes fast charging curve setting is invalid. --- flashes fast charging curve setting is invalid.
--- --- Power failure and/or no battery connected. --- --- Power failure and/or no battery connected.
Fill-up charge Fill-up charge
The fill-up charge begins automatically after the recharge procedure has ended. The fill-up charge begins automatically after the recharge procedure has ended.
Partial recharging Partial recharging
The battery charger is designed in such a way that it automatically adapts to the char- The battery charger is designed in such a way that it automatically adapts to the char-
ging status of partially recharged batteries. This permits to reduce wear and tear of ging status of partially recharged batteries. This permits to reduce wear and tear of
the battery. the battery.
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D6 D6
5 Removing and installing the battery 5 Removing and installing the battery
f The truck must stand horizontally. Batteries with exposed terminals or connectors
must be covered with a rubber mat to prevent short-circuits. Place battery connector
f The truck must stand horizontally. Batteries with exposed terminals or connectors
must be covered with a rubber mat to prevent short-circuits. Place battery connector
and battery cable in such a way that they do not get caught within the truck interior and battery cable in such a way that they do not get caught within the truck interior
when the battery is pulled out. when the battery is pulled out.
f When replacing batteries, ensure that a battery of the same type is fitted. Supplemen-
tary weights may not be removed or changed in their position.
f When replacing batteries, ensure that a battery of the same type is fitted. Supplemen-
tary weights may not be removed or changed in their position.
f After reinstallation of the battery, visually check all leads and connectors for damage.
f After reinstallation of the battery, visually check all leads and connectors for damage.
A When changing the battery with the aid of a lifting gear, ensure that the lifting gear is
of adequate capacity (the battery weight is indicated on the battery identification plate
A When changing the battery with the aid of a lifting gear, ensure that the lifting gear is
of adequate capacity (the battery weight is indicated on the battery identification plate
at the battery trough). The battery must be lifted vertically to prevent crushing of the at the battery trough). The battery must be lifted vertically to prevent crushing of the
battery trough. The hooks are to be attached to the battery hoisting ears (9) that they battery trough. The hooks are to be attached to the battery hoisting ears (9) that they
cannot fall onto the battery cells when the hoisting gear is released. cannot fall onto the battery cells when the hoisting gear is released.
5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device) 5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)
– Withdraw the battery connector. – Withdraw the battery connector.

– Attach hoisting gear to the hoisting ears (9). – Attach hoisting gear to the hoisting ears (9).
– Lift out the battery. – Lift out the battery.
9 9
The re-assembly can be performed by reversing the above actions; pay attention to The re-assembly can be performed by reversing the above actions; pay attention to
the correct mounting position and battery connection. the correct mounting position and battery connection.
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D7 D7
5.2 Remove battery by lifting it upwards (truck with wheel-arm lifting device) 5.2 Remove battery by lifting it upwards (truck with wheel-arm lifting device)
– Withdraw the battery connector (3). – Withdraw the battery connector (3).
f The battery cable of the truck must be laterally led outside. While removing the bat-
tery, make sure that the cable is not squeezed.
f The battery cable of the truck must be laterally led outside. While removing the bat-
tery, make sure that the cable is not squeezed.
– Attach hoisting gear to the hoisting ears (9). – Attach hoisting gear to the hoisting ears (9).
– Lift out the battery. – Lift out the battery.
9 3 9 3
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D8 D8
5.3 Lateral battery change (o) 5.3 Lateral battery change (o)
– Withdraw the battery connector. – Withdraw the battery connector.

– Pull the locking mechanism (12) of the battery cover upwards while firmly holding – Pull the locking mechanism (12) of the battery cover upwards while firmly holding
the battery cover (13). the battery cover (13).
– Lift out the battery cover (13) and keep it in a safe location. – Lift out the battery cover (13) and keep it in a safe location.
– Position battery trolley next to the truck. – Position battery trolley next to the truck.
– Push cautiously battery (11) from the truck onto the battery trolley / battery change – Push cautiously battery (11) from the truck onto the battery trolley / battery change
station. station.
f Be careful not to place your fingers between partition wall of the truck and the battery.
Heed the operating instructions of the battery change station.
f Be careful not to place your fingers between partition wall of the truck and the battery.
Heed the operating instructions of the battery change station.
Mounting the battery: Mounting the battery:
– Insert battery up to battery stop (10). – Insert battery up to battery stop (10).
– Press in the battery stop and keep it in that position. – Press in the battery stop and keep it in that position.
– Pull battery into the truck. – Pull battery into the truck.
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D9 D9
6 Combined instrument 6 Combined instrument
Battery discharge indicator: The di- Battery discharge indicator: The di-
scharging status of the battery is indica- scharging status of the battery is indica-
ted by 10 beams on battery icon (14) re- ted by 10 beams on battery icon (14) re-
presenting 10%-steps. 14 presenting 10%-steps. 14
As the discharge proceeds, the beams As the discharge proceeds, the beams
go out from top to bottom. go out from top to bottom.
m If maintenance-free batteries are used,

the instrument must be adjusted in such
T h
m If maintenance-free batteries are used,
the instrument must be adjusted in such
T h
a way that the T icon (17) appears next a way that the T icon (17) appears next
to the operating hours indicator. If this to the operating hours indicator. If this
setting is not selected, the battery may setting is not selected, the battery may
be damaged due to a complete dischar- be damaged due to a complete dischar-
ge. For adjusting the instrument, it is re- ge. For adjusting the instrument, it is re-
commended to consult the manufacturer 15 commended to consult the manufacturer 15
service. service.
When a remaining battery capacity of When a remaining battery capacity of

- 30% for standard batteries T h - 30% for standard batteries T h
- 50% for maintenance-free batteries - 50% for maintenance-free batteries
is reached, a “CAUTION” icon (15) is in- is reached, a “CAUTION” icon (15) is in-
dicated. dicated.
Recharging the battery is recommen- Recharging the battery is recommen-
ded. ded.
When a remaining battery capacity of 16 When a remaining battery capacity of 16

- 20% for standard batteries STOP - 20% for standard batteries STOP
- 40% for maintenance-free batteries - 40% for maintenance-free batteries
is reached, the “CAUTION” icon goes is reached, the “CAUTION” icon goes
out and a flashing “STOP” icon (16) ap- 17 out and a flashing “STOP” icon (16) ap- 17
T h T h
pears. pears.
After 5 min., the “STOP” icon box lights After 5 min., the “STOP” icon box lights
up permanently. Recharging the battery up permanently. Recharging the battery
is recommended. is recommended.
18 18
Battery discharge monitor: When the “STOP” icon is permanently lit, the lifting Battery discharge monitor: When the “STOP” icon is permanently lit, the lifting
function is switched off. function is switched off.
A The lifting function can only be re-activated, when the connected battery is at least
recharged by 70%.
A The lifting function can only be re-activated, when the connected battery is at least
recharged by 70%.
Operating hour meter: The operating hour meter (18) is integrated in the battery di- Operating hour meter: The operating hour meter (18) is integrated in the battery di-
scharge indicator and displays the overall operating time of all driving and lifting mo- scharge indicator and displays the overall operating time of all driving and lifting mo-
vements. vements.
A The digit to the right-hand side of the decimal point is flashing when the device is ac-
tive.
A The digit to the right-hand side of the decimal point is flashing when the device is ac-
tive.
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D 10 D 10
E Operation E Operation
1 Safety regulations governing the operation of the fork lift truck 1 Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his re- been trained in the operation of trucks, who have demonstrated to the user or his re-
presentative their capability of moving and handling loads, and who have expressly presentative their capability of moving and handling loads, and who have expressly
been charged by the user or his representative with the operation of the truck. been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork lift truck; and familiar with the contents and duties; trained in the operation of the fork lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him. of these operating instructions. All necessary rights must be granted to him.
If the fork lift truck can be used in the pedestrian-controlled mode, the driver must If the fork lift truck can be used in the pedestrian-controlled mode, the driver must
wear safety boots when operating the truck. wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck du- Prohibition of unauthorised use: The driver is responsible for the fork lift truck du-
ring working time. He must forbid unauthorised persons to drive or operate the fork ring working time. He must forbid unauthorised persons to drive or operate the fork
lift truck. The transport or lifting of persons is forbidden. lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attach- Damage and defects: Damage or defects noted on the fork lift truck or on the attach-
ments must immediately be brought to the notice of the person in charge. fork lift ments must immediately be brought to the notice of the person in charge. fork lift
trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)
must not be used until they have been properly repaired. must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed Repairs: Without specific training and express authorisation, the driver is not allowed
to perform any repairs or modifications on the fork lift truck. Under no circumstances to perform any repairs or modifications on the fork lift truck. Under no circumstances
must the driver change the setting of switches or safety installations or render them must the driver change the setting of switches or safety installations or render them
ineffective. ineffective.
Danger area: A “danger area” is considered to be the area within which persons are Danger area: A “danger area” is considered to be the area within which persons are
endangered by the travelling or lifting movements of the fork lift truck or its load lifting endangered by the travelling or lifting movements of the fork lift truck or its load lifting
devices (e.g. fork or attachments), or by the loads being transported. This also inclu- devices (e.g. fork or attachments), or by the loads being transported. This also inclu-
des the area within reach of falling loads or falling / lowering truck attachments. des the area within reach of falling loads or falling / lowering truck attachments.
f Unauthorised persons must be asked to leave the danger area. The driver must give
a warning signal whenever a situation presenting danger to persons might develop.
f Unauthorised persons must be asked to leave the danger area. The driver must give
a warning signal whenever a situation presenting danger to persons might develop.
The fork lift truck must immediately be brought to a standstill if persons, although as- The fork lift truck must immediately be brought to a standstill if persons, although as-
ked, do not leave the danger area. ked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded. notes described in the present operating instructions must always be heeded.
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2 Description of controls and indicating instruments 2 Description of controls and indicating instruments
Pos. Controls or EJC EJC-Z Function Pos. Controls or EJC EJC-Z Function
indicating instrument 14/16 14/16 indicating instrument 14/16 14/16
respectively respectively
1 Master switch t t The circuit is interrupted, all electric 1 Master switch t t The circuit is interrupted, all electric
(Emergency Stop) functions are switched off. The truck is (Emergency Stop) functions are switched off. The truck is
compulsory braked. compulsory braked.
2 Key switch t t Switches the control current on and 2 Key switch t t Switches the control current on and
off. When the key is removed from the off. When the key is removed from the
key switch, the truck cannot be opera- key switch, the truck cannot be opera-
ted by unauthorised persons. ted by unauthorised persons.
3 Combined instrument o o Indicates the remaining capacity of the 3 Combined instrument o o Indicates the remaining capacity of the
battery and the hours of operation that battery and the hours of operation that
truck has already performed (see truck has already performed (see
chapter D). chapter D).
4 Control shaft t t Steering and braking the truck. 4 Control shaft t t Steering and braking the truck.
5 Button - Shunt driving t t If the control shaft is in the upper bra- 5 Button - Shunt driving t t If the control shaft is in the upper bra-
king range, the braking function can be king range, the braking function can be
by-passed by pressing by-passed by pressing
this button. The truck can only be mo- this button. The truck can only be mo-
ved with reduced speed (shunt dri- ved with reduced speed (shunt dri-
ving). ving).
6 Button - wheel arms - t Wheel arms are lowered 6 Button - wheel arms - t Wheel arms are lowered
lowering with constant speed lowering with constant speed
7 Button - wheel arms - t Wheel arms are lifted 7 Button - wheel arms - t Wheel arms are lifted
lifting with constant speed lifting with constant speed
8 Driving regulator t t Controls the driving direction 8 Driving regulator t t Controls the driving direction
driving speed. driving speed.
9 Collision-guard t t Truck drives away from the operator 9 Collision-guard t t Truck drives away from the operator
button and stops. button and stops.
10 Button - t t Lifting the lifting device. 10 Button - t t Lifting the lifting device.
Lifting the lifting device The lifting speed can be continuously Lifting the lifting device The lifting speed can be continuously
adjusted with this key (adjustment ran- adjusted with this key (adjustment ran-
ge 8 mm). ge 8 mm).
11 Button - t t Lowering the lifting device. 11 Button - t t Lowering the lifting device.
Lowering the lifting de- The lowering speed can be conti- Lowering the lifting de- The lowering speed can be conti-
vice nuously adjusted with this key (adjust- vice nuously adjusted with this key (adjust-
ment range 8 mm). ment range 8 mm).
12 Button - warning signal t t Trigger warning signal. 12 Button - warning signal t t Trigger warning signal.
(horn) (horn)
13 Terminal strip t t Depositing of freight documents. 13 Terminal strip t t Depositing of freight documents.
14 Control lamp at the o - Indicates the loading states 14 Control lamp at the o - Indicates the loading states
battery charger (see chapter D). battery charger (see chapter D).
15 Integrated battery o - Used for recharging the battery 15 Integrated battery o - Used for recharging the battery
charger charger
16 Document case o o Used for depositing documents 16 Document case o o Used for depositing documents
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t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment
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5 12 5 12
6 11 6 11
7 10 7 10
8 8 8 8
9 9
13 13
4 4
14 14
3 3
15 15
2 2
1 1
16 16
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3 Putting vehicle in operation 3 Putting vehicle in operation
f Before starting or operating the truck, or before lifting any loads, the driver has to
make sure that nobody is within the danger area.
f Before starting or operating the truck, or before lifting any loads, the driver has to
make sure that nobody is within the danger area.
Checks and actions before routine start-up Checks and actions before routine start-up
– Visual inspection for damages of the whole truck (especially tyres and load carrying – Visual inspection for damages of the whole truck (especially tyres and load carrying
devices). devices).
– Visual inspection of battery fixing and cable connections. – Visual inspection of battery fixing and cable connections.
Starting up the truck Starting up the truck
– Pull out master switch (1). – Pull out master switch (1).
– Put key into the key switch (2) and turn right until stop to position “I”. – Put key into the key switch (2) and turn right until stop to position “I”.
The combined instrument (3) indicates the available battery capacity. The combined instrument (3) indicates the available battery capacity.
– Check function of horn (12). – Check function of horn (12).
– Check control shaft (4) for braking and driving function (see section 4.2). – Check control shaft (4) for braking and driving function (see section 4.2).
The truck is now ready for operation. The truck is now ready for operation.
12 12
4 4
3 3
2 2
1 1
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4 Operation of the fork lift truck 4 Operation of the fork lift truck
4.1 Safety regulations applicable when operating the truck 4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca- Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work ted for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose. areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con- Driving conduct: The travelling speed must be adapted to the prevailing local con-
ditions. The truck must be driven at slow speed when negotiating bends or narrow ditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must al- passages, when passing through swing doors and at blind spots. The driver must al-
ways observe an adequate braking distance between the fork lift truck and the vehicle ways observe an adequate braking distance between the fork lift truck and the vehicle
in front and he must be in control of his truck at all times. Sudden stopping (except in in front and he must be in control of his truck at all times. Sudden stopping (except in
emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit- emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit-
ted. It is forbidden to lean out of or reach beyond the working and operating area. ted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the fork lift truck view of the route ahead. When loads blocking the view are carried, the fork lift truck
must be driven with the load at the rear. If this is not possible, a second person must must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the fork lift truck to give suitable warnings. walk in front of the fork lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted
only when they are recognised lanes, when they are clean and non-slipping, and only when they are recognised lanes, when they are clean and non-slipping, and
when the technical specification of the truck permits safe driving on such slopes or when the technical specification of the truck permits safe driving on such slopes or
inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, inclines. Loads must always be carried at that end of the truck facing uphill. U-turns,
cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or
inclines is not permitted. Inclines must only be negotiated at slow speed, with the inclines is not permitted. Inclines must only be negotiated at slow speed, with the
driver ready to brake at any moment. driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used if they are of adequate load bearing capacity, if suitable for driving on, and if be used if they are of adequate load bearing capacity, if suitable for driving on, and if
authorised by the user of the truck for truck traffic. The fork lift truck driver has to sa- authorised by the user of the truck for truck traffic. The fork lift truck driver has to sa-
tisfy himself accordingly before driving into lifts or on to loading platforms. The truck tisfy himself accordingly before driving into lifts or on to loading platforms. The truck
must enter lifts with the load in front and must take up a position which does not allow must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft. it to come into contact with the walls of the lift shaft.
Persons riding in the lift together with the fork lift truck must only enter the lift after the Persons riding in the lift together with the fork lift truck must only enter the lift after the
fork lift truck has come safely to a standstill, and must leave the lift before the fork lift fork lift truck has come safely to a standstill, and must leave the lift before the fork lift
truck. truck.
Nature of the loads carried: Only loads that have been safely and correctly secured Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carria- must be carried. Never transport loads stacked higher than the top of the fork carria-
ge, or stacked higher than the guard grille. ge, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork lift truck for braked and/ Towing trailers: The maximum trailer load given for the fork lift truck for braked and/
or unbraked trailers must not be exceeded. The trailer load must be properly secured or unbraked trailers must not be exceeded. The trailer load must be properly secured
and must not exceed the dimensions permitted for the driving routes. After attaching and must not exceed the dimensions permitted for the driving routes. After attaching
the trailer but before starting driving, the driver must check that the trailer attachment the trailer but before starting driving, the driver must check that the trailer attachment
is secured against detachment. Towing fork lift trucks must be operated in such a is secured against detachment. Towing fork lift trucks must be operated in such a
manner that safe driving and braking of the truck and the trailer is guaranteed for all manner that safe driving and braking of the truck and the trailer is guaranteed for all
driving movements. driving movements.
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4.2 Driving, steering, braking 4.2 Driving, steering, braking
f Increased attention has to be paid during driving and steering the truck, especially if
movements outside of the truck contour are to be performed.
f Increased attention has to be paid during driving and steering the truck, especially if
movements outside of the truck contour are to be performed.
It is not admissible to stay on the vehicle during driving. It is not admissible to stay on the vehicle during driving.
Driving with load lifting devices or loads lifted higher than the ground clearance di- Driving with load lifting devices or loads lifted higher than the ground clearance di-
stance is only permitted when the load is to be picked up or to be lowered to the stance is only permitted when the load is to be picked up or to be lowered to the
ground. From a certain type dependant lift height, the drive speed is automatically re- ground. From a certain type dependant lift height, the drive speed is automatically re-
duced during lifting and increased again during lowering. duced during lifting and increased again during lowering.
EMERGENCY STOP EMERGENCY STOP

– Push master switch (1) down. – Push master switch (1) down.
All electric functions are switched off. The truck is compulsory braked. All electric functions are switched off. The truck is compulsory braked.
Emergency stop Emergency stop

When the control shaft (4) is released, the truck is compulsory braked (emergency When the control shaft (4) is released, the truck is compulsory braked (emergency
stop) - the control shaft (4) automatically swivels into the upper braking range (B). stop) - the control shaft (4) automatically swivels into the upper braking range (B).
f If the control shaft (4) swivels only slowly into the braking position, it is required to per-
form troubleshooting measures. For example, the return spring must be exchanged!
f If the control shaft (4) swivels only slowly into the braking position, it is required to per-
form troubleshooting measures. For example, the return spring must be exchanged!
9 9
4 4
R R
8 B 8 B
0 0
F F
V V
B B
R R
V 1 V 1
Driving Driving
f Do not drive the truck unless the hoods are closed and locked in the stipulated man-
ner. When driving through swinging doors, etc., make sure that the doors do not trig-
f Do not drive the truck unless the hoods are closed and locked in the stipulated man-
ner. When driving through swinging doors, etc., make sure that the doors do not trig-
ger the collision-guard button (9). ger the collision-guard button (9).
– Commissioning the truck (see section 3). – Commissioning the truck (see section 3).
– Push the control shaft (4) into the driving range (F) and set the driving switch (8) to – Push the control shaft (4) into the driving range (F) and set the driving switch (8) to
the desired driving direction (V or R). the desired driving direction (V or R).
The truck starts to drive into the selected direction. The truck starts to drive into the selected direction.
A The driving speed can be continuously regulated with the driving switch (8). A The driving speed can be continuously regulated with the driving switch (8).
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f If the truck can only be moved with reduced driving speed, a defect has occurred
which is influencing the safety of operation of the truck. It may be that the service bra-
f If the truck can only be moved with reduced driving speed, a defect has occurred
which is influencing the safety of operation of the truck. It may be that the service bra-
ke can only be used after pressing the EMERGENCY-STOP switch (1). ke can only be used after pressing the EMERGENCY-STOP switch (1).
The truck needs to be taken out of service and must be repaired by expert personnel The truck needs to be taken out of service and must be repaired by expert personnel
Driving on slopes Driving on slopes
m The load must be transported pointing towards the mountain!

m The load must be transported pointing towards the mountain!
Securing the truck against “rolling downhill”: Securing the truck against “rolling downhill”:
If the driving switch is set to zero, the service brake is automatically triggered when If the driving switch is set to zero, the service brake is automatically triggered when
the truck starts to roll downhill (the control system detects the unintended movement the truck starts to roll downhill (the control system detects the unintended movement
of the truck). The driving switch can be used to release the service brake and to select of the truck). The driving switch can be used to release the service brake and to select
the desired driving speed and direction. the desired driving speed and direction.
f If the roll-off brake was deactivated by the service, only service brake and counterflow
brake are available.
Steering Steering
– Swivelling the control shaft to the left-hand or right-hand side. – Swivelling the control shaft to the left-hand or right-hand side.
Shunt driving Shunt driving
f The driver must pay special attention if he uses the “Shunt driving” button (5).
f The driver must pay special attention if he uses the “Shunt driving” button (5).
The truck can be moved with its control shaft (4) in ver- The truck can be moved with its control shaft (4) in ver-
tical position (e.g. in confined spaces / lifts): tical position (e.g. in confined spaces / lifts):
4 4
– Press “Shunt driving” button (5). – Press “Shunt driving” button (5).
– Set the driving switch (8) to the desired driving direc- – Set the driving switch (8) to the desired driving direc-
tion (V or R). tion (V or R).
The service brake is triggered. The truck changes to The service brake is triggered. The truck changes to
the slow-driving mode. the slow-driving mode.
5 8 8 5 8 8
m The service brake is only activated after releasing the

“Shunt driving” button; in the Shunt driving mode, braking is only possible using the
m The service brake is only activated after releasing the
“Shunt driving” button; in the Shunt driving mode, braking is only possible using the
counterflow brake (driving switch (8)). counterflow brake (driving switch (8)).
f In case of danger, the truck can be immediately braked by releasing the “Shunt dri-
ving” button (5).
f In case of danger, the truck can be immediately braked by releasing the “Shunt dri-
ving” button (5).
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Braking Braking
f The braking effect of the truck is mainly depending on the road surface. This must be
taken into account by the driver for his driving behavior.
f The braking effect of the truck is mainly depending on the road surface. This must be
taken into account by the driver for his driving behavior.
The truck may be braked in three ways: The truck may be braked in three ways:
– Using the service brake (control shaft (4)), – Using the service brake (control shaft (4)),
– Using dynamic braking (roll-off brake can be adjusted by the service), – Using dynamic braking (roll-off brake can be adjusted by the service),
– Control with regenerative brake via the drive control (8). – Control with regenerative brake via the drive control (8).
A For standard driving operations, only the dynamic brake and that counterflow brake
are to be used, since these brake types are reduce wear and tear and help to save
A For standard driving operations, only the dynamic brake and that counterflow brake
are to be used, since these brake types are reduce wear and tear and help to save
energy (energy return supply). energy (energy return supply).
Braking with the service brake: Braking with the service brake:
f In case of danger, the truck must be braked with the service brake (control shaft (4)).
f In case of danger, the truck must be braked with the service brake (control shaft (4)).
– Swivel control shaft (4) upwards or downwards into one of the braking ranges (B). – Swivel control shaft (4) upwards or downwards into one of the braking ranges (B).
The drive motor is mechanically braked. The drive motor is mechanically braked.
A When the control shaft (4) is released, it swivels into the upper braking range (B).If
the truck is parked, the service brake is used as parking brake
A When the control shaft (4) is released, it swivels into the upper braking range (B).If
the truck is parked, the service brake is used as parking brake
9 9
4 4
R R
8 B 8 B
0 0
F F
V V
B B
R R
V 1 V 1
Dynamic braking (roll-off brake): Dynamic braking (roll-off brake):
– After releasing the driving switch (8) - driving switch set to zero - the truck is braked – After releasing the driving switch (8) - driving switch set to zero - the truck is braked
with the help of the dynamic brake (roll-off brake), depending on the selected set- with the help of the dynamic brake (roll-off brake), depending on the selected set-
ting. ting.
Braking with the counterflow brake: Braking with the counterflow brake:
m If the control system or driving mechanism breaks down, the counterflow brake beco-
mes ineffective.
m If the control system or driving mechanism breaks down, the counterflow brake beco-
mes ineffective.
– Do not turn the drive control (8) into opposite driving direction. – Do not turn the drive control (8) into opposite driving direction.
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A The braking effect depends on the position of the driving switch. A The braking effect depends on the position of the driving switch.
E8 E8
4.3 Picking up or lowering load units 4.3 Picking up or lowering load units
f Before a load unit is picked up, the driver has to make sure that it is properly palletised
and does not exceed the permitted bearing capacity of the truck.
f Before a load unit is picked up, the driver has to make sure that it is properly palletised
and does not exceed the permitted bearing capacity of the truck.
Do not grab into the hoist frame during lifting and lowering. Do not grab into the hoist frame during lifting and lowering.
– Drive the truck with the fork tines as far as possible below the load unit. – Drive the truck with the fork tines as far as possible below the load unit.
It is not permitted to pick up long goods with the truck driving transversally below It is not permitted to pick up long goods with the truck driving transversally below
the good. the good.
A The double-two lifting hoist frame (ZZ) and the triple-two hoist frame (DZ) the first lif-
ting movement of the load carriage (free lifting capacity) is realised without changing
A The double-two lifting hoist frame (ZZ) and the triple-two hoist frame (DZ) the first lif-
ting movement of the load carriage (free lifting capacity) is realised without changing
the overall height with the help of a short free-lifting cylinder which is centrally arran- the overall height with the help of a short free-lifting cylinder which is centrally arran-
ged. ged.
From a specific lifting height onwards (depending on the design), the driving speed is From a specific lifting height onwards (depending on the design), the driving speed is
automatically reduced when the lifting movement is performed and increased when automatically reduced when the lifting movement is performed and increased when
the lowering movement is started. the lowering movement is started.
Lifting Lifting
– Press the “Lift the lifting device” button – Press the “Lift the lifting device” button
(10) until the desired height has been (10) until the desired height has been
reached. reached.
Lowering Lowering
– Press the “Lower the lifting device” – Press the “Lower the lifting device”
button (11) until the desired height has button (11) until the desired height has
been reached. been reached.
A The lifting/lowering speed can be conti-

nuously adjusted with this button (adju-
A The lifting/lowering speed can be conti-
nuously adjusted with this button (adju-
10 11 10 11
stment range 8 mm). stment range 8 mm).
Small button adjustment range = slow lifting / lowering Small button adjustment range = slow lifting / lowering
Large button adjustment range = fast lifting / lowering Large button adjustment range = fast lifting / lowering
m Avoid any abrupt lowering of the load unit.

m Avoid any abrupt lowering of the load unit.
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Wheel-arm lifting device (o) Wheel-arm lifting device (o)
A The “Lift wheel arms” and “Lower wheel arms” can be used to perform the lifting or
lowering movement with a fixed speed.
A The “Lift wheel arms” and “Lower wheel arms” can be used to perform the lifting or
lowering movement with a fixed speed.
f To ensure the stability of the truck, the wheel arms will be automatically lowered from
a specific lifting height of the fork onwards, depending on the used hoist frame type.
f To ensure the stability of the truck, the wheel arms will be automatically lowered from
a specific lifting height of the fork onwards, depending on the used hoist frame type.
From this lifting height onwards, the wheel-arm lifting device can no longer be used. From this lifting height onwards, the wheel-arm lifting device can no longer be used.
The lowering movement cannot be interrupted! (Danger of injuries) The lowering movement cannot be interrupted! (Danger of injuries)
Lifting the wheel arms Lifting the wheel arms

– Press the “Lift wheel arms” (7) button. – Press the “Lift wheel arms” (7) button.
– Keep the button pressed, until the – Keep the button pressed, until the
desired lifting height has been rea- desired lifting height has been rea-
ched. ched.
Lowering the wheel arms Lowering the wheel arms
– Press the “Lower wheel arms” (6) but- – Press the “Lower wheel arms” (6) but-
ton. ton.
– Keep the button pressed, until the – Keep the button pressed, until the
desired lowering height has been rea- desired lowering height has been rea-
ched. ched.
6 7 6 7
Emergency lowering system Emergency lowering system
f The emergency lowering system may only be used if there are no persons within the
danger zone.
f The emergency lowering system may only be used if there are no persons within the
danger zone.
If the lifting device can no longer be lowered due to a defect in the lifting control sy- If the lifting device can no longer be lowered due to a defect in the lifting control sy-
stem, the emergency lowering system has to be activated. stem, the emergency lowering system has to be activated.
– Set key switch (2) to its “0” position – Set key switch (2) to its “0” position
and set the master switch (1) to its and set the master switch (1) to its
“OFF” position. “OFF” position.
– Pull the battery connector – Pull the battery connector
(see chapter D). (see chapter D).
– Open the front hood – Open the front hood
– Loosen the screw on the valve group – Loosen the screw on the valve group
(17). (17).
A The required Allen key (2.5 mm) can be

found at the valve group.
A The required Allen key (2.5 mm) can be
found at the valve group.
The lifting device is lowered. 17 The lifting device is lowered. 17
– Retighten the screw (17) after the emergency lowering procedure has been perfor- – Retighten the screw (17) after the emergency lowering procedure has been perfor-
med. med.
f The truck may only be retaken into service after the required troubleshooting measu-
res were successfully performed.
f The truck may only be retaken into service after the required troubleshooting measu-
res were successfully performed.
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4.4 Safe parking of the truck 4.4 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered If the truck is left unattended, even for only short periods of time, it must be rendered
safe. safe.
f Do not park the truck on slopes! The lifting device must always be completely lowe-
red.
f Do not park the truck on slopes! The lifting device must always be completely lowe-
red.
– Bring control shaft (4) into brake position (B). – Bring control shaft (4) into brake position (B).
– Lowering the lifting device. – Lowering the lifting device.
– Set key switch (2) to “0” position and remove the key. – Set key switch (2) to “0” position and remove the key.
– Set master switch (1) to “OFF” position. – Set master switch (1) to “OFF” position.
4.5 Fault location 4.5 Fault location
This chapter helps the operator to locate and fix simple malfunctions or the results of This chapter helps the operator to locate and fix simple malfunctions or the results of
operating errors him- or herself. The order of the work stated in the table must be ob- operating errors him- or herself. The order of the work stated in the table must be ob-
served for fault location. served for fault location.
Fault Possible cause Remedy Fault Possible cause Remedy

Truck does not – Battery connector – Check the battery connector Truck does not – Battery connector – Check the battery connector
move not connected and reconnect it, if necessary move not connected and reconnect it, if necessary
– Master switch (EMERGENCY – Release – Master switch (EMERGENCY – Release
STOP) master switch (EMERGENCY STOP) master switch (EMERGENCY
pressed STOP) pressed STOP)
– Key switch set to “0“ position – Set the key switch to position “I” – Key switch set to “0“ position – Set the key switch to position “I”
– Battery voltage too low – Check the charging status of – Battery voltage too low – Check the charging status of
the battery the battery
and recharge, if necessary and recharge, if necessary
– Control shaft not swivelled into – Swivel control shaft into driving – Control shaft not swivelled into – Swivel control shaft into driving
driving range (F) range (F) driving range (F) range (F)
– Faulty fuse – Check – Faulty fuse – Check
fuses F1 and 1F1 fuses F1 and 1F1
– Truck battery charger is con- – Disconnect the truck battery – Truck battery charger is con- – Disconnect the truck battery
nected charger nected charger
from the mains from the mains
Load cannot – Truck not ready for operation – Perform all troubleshooting Load cannot – Truck not ready for operation – Perform all troubleshooting
be lifted measures that are mentioned be lifted measures that are mentioned
under “truck does not drive” under “truck does not drive”
– Hydraulic oil level too low – Check hydraulic oil level – Hydraulic oil level too low – Check hydraulic oil level
– Faulty fuse – Check fuse 2F1 – Faulty fuse – Check fuse 2F1
– load too high – Pay attention to the maximum – load too high – Pay attention to the maximum
bearing capacity (see identifi- bearing capacity (see identifi-
cation label) cation label)
– Discharge monitor is triggered – Check the charging status of – Discharge monitor is triggered – Check the charging status of
(STOP icon) the battery (STOP icon) the battery
and recharge, if necessary and recharge, if necessary
f If it is not possible to rectify the fault by performing the indicated “remedial actions”,
f If it is not possible to rectify the fault by performing the indicated “remedial actions”,
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please contact the Customer Service, as more intricate faults can only be rectified by please contact the Customer Service, as more intricate faults can only be rectified by
specially trained and qualified service personnel. specially trained and qualified service personnel.
E 11 E 11
E 12
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E 12
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F Maintenance of the fork lift truck F Maintenance of the fork lift truck
1 Operational safety and environmental protection 1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists. accordance with the intervals as indicated in the servicing checklists.
f Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
f Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
m Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-
m Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-
turer must be used. Used parts, oils and fuels must be disposed of in accordance with turer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you. of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F). the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance 2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of thus recommend signing a maintenance contract with the relevant service location of
the manufacturer. the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tip- jacked up, suitable measures must be taken to prevent the truck from slipping or tip-
ping over (use of wedges, wooden blocks). Work underneath the raised load lifting ping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength. chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are re- lift truck. Prior to commencing cleaning operations, all safety measures that are re-
quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope- quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope-
rated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com- rated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-
pressed air and non-conducting, antistatic brushes must be used for the cleaning of pressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies. electric or electronic assemblies.
m If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
m If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning. moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis- Upon completion of cleaning work, the operations detailed in the section “Recommis-
sioning” must be performed. sioning” must be performed.
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F1 F1
Work on the electric system: Work on the electric system of the truck must only be Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depowe- have to be taken. For battery-operated fork lift trucks, the truck must also be depowe-
red by removing the battery plug. red by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are these have to be removed from the fork lift truck before any welding operations are
undertaken. undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained. assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour Tyres: The quality of the tyres greatly affects the stability and the driving behaviour
of the fork-lift truck. The factory-mounted tyres must only be replaced by original spa- of the fork-lift truck. The factory-mounted tyres must only be replaced by original spa-
re parts of the manufacturer, since otherwise the specification of the data sheet re parts of the manufacturer, since otherwise the specification of the data sheet
cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift
truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and
right together). right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubri- checklist apply to normal duty. If requirements are higher (dust, temperature), lubri-
cation is required more often. The specified chain spray must be used as specified. cation is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-
draulic components, also renew the hoses in this hydraulic system. draulic components, also renew the hoses in this hydraulic system.
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F2 F2
3 Servicing and inspection 3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe Thorough and expert servicing is one of the most important preconditions for safe
operation of the fork lift truck. The neglect of regular servicing intervals can lead to operation of the fork lift truck. The neglect of regular servicing intervals can lead to
fork lift truck failure and constitutes a potential hazard to personnel and equipment. fork lift truck failure and constitutes a potential hazard to personnel and equipment.
m The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large tem-
m The indicated servicing intervals are based on single-shift operation under normal
operating conditions. For applications in dusty environments, or involving large tem-
perature fluctuations or multiple-shift operation, the servicing intervals must be shor- perature fluctuations or multiple-shift operation, the servicing intervals must be shor-
tened accordingly. tened accordingly.
The following servicing checklist indicates the operations to be performed and the re- The following servicing checklist indicates the operations to be performed and the re-
spective intervals to be observed. The servicing intervals are defined as follows: spective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week W1 = every 50 operating hours, but at least once per week
M3 = every 500 operating hours, but at least every 3 months M3 = every 500 operating hours, but at least every 3 months
A The W1 maintenance intervals must be carried out by the operator / customer. A The W1 maintenance intervals must be carried out by the operator / customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary. must check the wheel nuts/bolts and re-tighten if necessary.
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F3 F3
4 Maintenance checklist. 4 Maintenance checklist.
Maintenance intervals Maintenance intervals

Standard = t W M M M Standard = t W M M M
Cold-storage depot = k 1 3 6 12 Cold-storage depot = k 1 3 6 12
Chassis/ 1.1 Check all load bearing elements for damage t Chassis/ 1.1 Check all load bearing elements for damage t
Design: 1.2 Check all bolted connections t Design: 1.2 Check all bolted connections t
Drive unit: 2.1 Check the transmission for noises and leakage t Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Check the transmission oil level t 2.2 Check the transmission oil level t
2.3 Change the gear oil k t 2.3 Change the gear oil k t
Wheels: 3.1 Check for wear and damage t Wheels: 3.1 Check for wear and damage t
3.2 Check seating and attachment k t 3.2 Check seating and attachment k t
Steering: 4.1 Check the steering clearance t Steering: 4.1 Check the steering clearance t
Brake 5.1 Check for correct function and adjustment k t Brake 5.1 Check for correct function and adjustment k t
system: 5.2 Check the return spring for repositioning function and t system: 5.2 Check the return spring for repositioning function and t
damage damage
5.3 Check the brake linings for wear t 5.3 Check the brake linings for wear t
5.4 Check the brake linkage; adjust and grease, k t 5.4 Check the brake linkage; adjust and grease, k t
if necessary if necessary
Hoist frame: 6.1 Visual check of rollers, slide pieces and stops k t Hoist frame: 6.1 Visual check of rollers, slide pieces and stops k t
6.2 Check fork tines and fork carrier for wear and damage k t 6.2 Check fork tines and fork carrier for wear and damage k t
6.3 Check secure attachment of hoist frame t 6.3 Check secure attachment of hoist frame t
6.4 Check lift chains and chain guide for wear, adjust and t 6.4 Check lift chains and chain guide for wear, adjust and t
grease them. grease them.
6.5 Check the lateral clearance of the mast profiles and t 6.5 Check the lateral clearance of the mast profiles and t
whether they are parallel to each other whether they are parallel to each other
6.6 Check safety devices for proper attachment k t 6.6 Check safety devices for proper attachment k t
and damages and damages
Lifting device: 7.1 Check function, wear and tear and adjustment t Lifting device: 7.1 Check function, wear and tear and adjustment t
7.2 Visual check of rollers, slide pieces and stops k t 7.2 Visual check of rollers, slide pieces and stops k t
7.3 Check fork tines and fork carrier for wear and damage k t 7.3 Check fork tines and fork carrier for wear and damage k t
Hydr. system: 8.1 Check function k t Hydr. system: 8.1 Check function k t
8.2 Check all connections for leakage and damage k t 8.2 Check all connections for leakage and damage k t
8.3 Check hydraulic cylinders for leakage, damage and k t 8.3 Check hydraulic cylinders for leakage, damage and k t
secure attachment secure attachment
8.4 Check the oil level k t 8.4 Check the oil level k t
8.5 Change hydraulic oil k t 8.5 Change hydraulic oil k t
8.6 Change filter t 8.6 Change filter t
8.7 Check the pressure relief valves for correct functioning k t 8.7 Check the pressure relief valves for correct functioning k t
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F4 F4
Maintenance intervals Maintenance intervals
Standard = t W M M M Standard = t W M M M
Cold-storage depot = k 1 3 6 12 Cold-storage depot = k 1 3 6 12
Electr. 9.1 Check function t Electr. 9.1 Check function t
system: 9.2 Check all cables for secure connection and damage t system: 9.2 Check all cables for secure connection and damage t
9.3 Check the fuses for correct amperage t 9.3 Check the fuses for correct amperage t
9.4 Check switches and trip cams for proper functioning and t 9.4 Check switches and trip cams for proper functioning and t
seating seating
9.5 Check contactors and relays, replace wearing parts, t 9.5 Check contactors and relays, replace wearing parts, t
9.6 Check functioning of warning devices and safety circuits k t 9.6 Check functioning of warning devices and safety circuits k t
Electric 10.1 Check wear of carbon brushes t Electric 10.1 Check wear of carbon brushes t
motors: 10.2 Check the motor for secure attachment t motors: 10.2 Check the motor for secure attachment t
10.3 Suck out engine block, check wear of collector k t 10.3 Suck out engine block, check wear of collector k t
Battery: 11.1 Check acid density, acid level and cell voltage k t Battery: 11.1 Check acid density, acid level and cell voltage k t
11.2 Check the terminals for secure attachment and apply k t 11.2 Check the terminals for secure attachment and apply k t
pole grease pole grease
11.3 Clean battery connections, check for tight fit k t 11.3 Clean battery connections, check for tight fit k t
11.4 Check the battery cables for damage and replace, t 11.4 Check the battery cables for damage and replace, t
Lubrication 12.1 Grease truck according to lubrication schedule k t Lubrication 12.1 Grease truck according to lubrication schedule k t
service: service:
General mea- 13.1 Check electrical system for short to ground t General mea- 13.1 Check electrical system for short to ground t
surements: 13.2 Check driving speed and braking distance t surements: 13.2 Check driving speed and braking distance t
13.3 Check lifting and lowering speed t 13.3 Check lifting and lowering speed t
13.4 Check safety facilities and switch-off devices t 13.4 Check safety facilities and switch-off devices t
Demonstrati- 14.1 Perform a trial run under a nominal load t Demonstrati- 14.1 Perform a trial run under a nominal load t
on: 14.2 Demonstrate the truck to a person charged with inspec- k t on: 14.2 Demonstrate the truck to a person charged with inspec- k t
tion upon completion of the maintenance of the truck tion upon completion of the maintenance of the truck
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F5 F5
5 Lubrication schedule 5 Lubrication schedule
E F E F
G G
2) 2)
E F E F
E F E F
1) 1)
B B+C B B+C
1,4l 1) 1,4l 1)
A A+C A A+C
3) 3)
MA=105Nm MA=105Nm
g Slide faces g Slide faces

s Grease nipple s Grease nipple
Filler neck for hydraulic oil Filler neck for hydraulic oil
b Filler neck Gear oil b Filler neck Gear oil
a Drain plug Gear oil a Drain plug Gear oil
1) Mixing proportion for application in cold-storage depots 1:1 1) Mixing proportion for application in cold-storage depots 1:1
2) Tandem load wheel 2) Tandem load wheel
3) Filling level see “Check hydraulic oil level” 3) Filling level see “Check hydraulic oil level”
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F6 F6
5.1 Fuels, coolants and lubricants 5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed. handled properly. Manufacturer's instructions to be observed.
f Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, the-
f Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, the-
refore, must not come into contact with hot components or open fire. refore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mi- to mix consumption type materials of different grades or qualitiies resp., except if mi-
xing is expressively prescribed in these operating instructions. xing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be dis- agent, and the mixture of consumption type material and binding agent is to be dis-
posed of according to the regulations. posed of according to the regulations.
Code Order-no. Supply Qty Designation Used for: Code Order-no. Supply Qty Designation Used for:
A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system
B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission, C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission,
hydraulic system hydraulic system
E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication
F 29 200 100 1,0 kg Grease, TTF52 Lubrication F 29 200 100 1,0 kg Grease, TTF52 Lubrication
Grease Data Grease Data
Code Saponification Dropp. Worked penetr. NLG1 class Service tempe- Code Saponification Dropp. Worked penetr. NLG1 class Service tempe-
point °C at 25° C rat. °C point °C at 25° C rat. °C
E Lithium 185 265-295 2 -35/+120 E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100 F -- -- 310-340 1 -52/+100
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F7 F7
6 Notes on maintenance 6 Notes on maintenance
6.1 Preparation of the truck for servicing and maintenance operation 6.1 Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of All required safety measures must be taken to prevent any accidents in the course of
the servicing and maintenance operations. The following preparatory operations the servicing and maintenance operations. The following preparatory operations
must be performed: must be performed:
– Disconnect the battery connector to prevent accidental or unauthorised truck ope- – Disconnect the battery connector to prevent accidental or unauthorised truck ope-
ration. ration.
f When work has to be performed under the jacked-up truck, suitable measures must
be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck,
f When work has to be performed under the jacked-up truck, suitable measures must
be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck,
the instructions included in chapter “Transportation and Commissioning” have to be the instructions included in chapter “Transportation and Commissioning” have to be
observed. observed.
6.2 Open the battery hood 6.2 Open the battery hood
See chapter D. See chapter D.
6.3 Open the front hood 6.3 Open the front hood
– Turn the control shaft to the truck outer edge or incline it slightly. – Turn the control shaft to the truck outer edge or incline it slightly.
– Release the hood locking mechanism (1); the key (2) can be found in the battery – Release the hood locking mechanism (1); the key (2) can be found in the battery
compartment. compartment.
– Raise the hood (3) and place it next to the truck. – Raise the hood (3) and place it next to the truck.
A Mounting is performed in reverse order

.
A Mounting is performed in reverse order
.
1 1
2 2
5 5
4 4
3 3
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F8 F8
6.4 Check hydraulic oil level 6.4 Check hydraulic oil level
– Prepare the truck for servicing and maintenance operations (refer to chapter F, sec- – Prepare the truck for servicing and maintenance operations (refer to chapter F, sec-
tion 6.1). tion 6.1).
– Open the front hood (see section 6.3). – Open the front hood (see section 6.3).
– Check the hydraulic oil level of the hydraulic tank (see section 5). – Check the hydraulic oil level of the hydraulic tank (see section 5).
A There are markings on the hydraulic tank (see section 5). The oil level must be chek-
ked with the lifting device being lowered.
A There are markings on the hydraulic tank (see section 5). The oil level must be chek-
ked with the lifting device being lowered.
– If required, top up with hydraulic oil with the required characteristics – If required, top up with hydraulic oil with the required characteristics
(see section 6.4; see table) (see section 6.4; see table)
Marking Litre Lifting heights (h3) Marking Litre Lifting heights (h3)
E ZT ZZ DZ E ZT ZZ DZ
Upper edge approx. 10.5 - - - up to 5350 Upper edge approx. 10.5 - - - up to 5350
4 approx. 10 - - - - 4 approx. 10 - - - -
3 approx. 8.3 - - up to 4300 up to 4300 3 approx. 8.3 - - up to 4300 up to 4300
2 approx. 6.8 - up to 4300 up to 3600 - 2 approx. 6.8 - up to 4300 up to 3600 -
1 approx. 5.1 all up to 3200 up to 2500 - 1 approx. 5.1 all up to 3200 up to 2500 -
A Mounting is performed in reverse order. A Mounting is performed in reverse order.
6.5 Check the transmission oil level 6.5 Check the transmission oil level
– Prepare the truck for servicing and maintenance operations (see section 6.3). – Prepare the truck for servicing and maintenance operations (see section 6.3).
– Loosen 2 x screws (5) using the key (2). – Loosen 2 x screws (5) using the key (2).
– Remove carefully the wheel cover (4). – Remove carefully the wheel cover (4).
– Check gear-oil level - oil level must reach the filler neck – Check gear-oil level - oil level must reach the filler neck
(see section 5). (see section 5).
– If required, top up with gear oil with the required characteristics (see section 5). – If required, top up with gear oil with the required characteristics (see section 5).
6.6 Exchanging the coarse sieve 6.6 Exchanging the coarse sieve
– Preparation of the truck for servicing – Preparation of the truck for servicing
and maintenance operations and maintenance operations
(refer to chapter F, section 6.1). (refer to chapter F, section 6.1).
– Loosen the screwed connection (6). – Loosen the screwed connection (6).
– Pull off the connection (7) and remove – Pull off the connection (7) and remove
the coarse sieve. the coarse sieve.
– Insert a new coarse sieve. – Insert a new coarse sieve.
A Tighten screwed connection (6) with

max. 60+10 Nm.
6 7
A Tighten screwed connection (6) with
max. 60+10 Nm.
6 7
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F9 F9
6.7 Checking the electric fuses 6.7 Checking the electric fuses
– Preparation of the truck for servicing and maintenance operations – Preparation of the truck for servicing and maintenance operations
(refer to section 6.1). (refer to section 6.1).
– Open the front hood – Open the front hood
(see section 6.3). (see section 6.3).
– Referring to the table, check all fuses for correct rating and replace, where required. – Referring to the table, check all fuses for correct rating and replace, where required.
12 12
8 8
11 11
10 9 10 9
Item Description Protection of: Value Item Description Protection of: Value
8 F1 Total control fuse 10 A 8 F1 Total control fuse 10 A
9 1F1 Drive motor (in parallel to 1F10) 150 A 9 1F1 Drive motor (in parallel to 1F10) 150 A
10 2F1 Pump motor 150 A 10 2F1 Pump motor 150 A
11 1F10 Drive motor (in parallel to 1F1) 40 A 11 1F10 Drive motor (in parallel to 1F1) 40 A
12 6F1 Discharge indicator/operating hour meter 10 A 12 6F1 Discharge indicator/operating hour meter 10 A
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F 10 F 10
6.8 Recommissioning the truck 6.8 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance Recommissioning of the truck following the performance of cleaning or maintenance
work is permitted only after the following operations have been performed: work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the horn for proper functioning.
– Check the master switch for correct functioning. – Check the master switch for correct functioning.
– Check the brake for correct functioning. – Check the brake for correct functioning.
– Lubricate truck according to lubrication schedule. – Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck 7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be par- If the fork lift truck is to be decommissioned for more than two months, it must be par-
ked in a frost-free and dry location and all measures to be taken before, during and ked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below. following decommissioning must be performed as detailed below.
m During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
m During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage. bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional mea- If the fork lift truck is to be decommissioned for more than 6 months, additional mea-
sures must be discussed with the Service Department of the manufacturer. sures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning 7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck. – Thoroughly clean the fork lift truck.
– Check the brakes for correct function. – Check the brakes for correct function.
– Check the hydraulic oil level and top up if required (refer to chapter F). – Check the hydraulic oil level and top up if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating. – Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F). – Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D). – Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles. – Disconnect and clean the battery. Apply pole grease to the battery poles.
A In addition to this, all instructions given by the battery supplier must be observed. A In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray. – Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning 7.2 Measures to be taken during decommissioning
Every 2 months: Every 2 months:

m Battery-operated fork lift trucks:

Regular recharging of the battery is very important; otherwise, exhaustive depletion
m Battery-operated fork lift trucks:
Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery. result in the destruction of the battery.
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F 11 F 11
7.3 Recommissioning the truck 7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck. – Thoroughly clean the fork lift truck.
– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. battery.
– Check if the gear oil contains condensed water and change if required. – Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E). – Start up the fork lift truck (refer to chapter E).
A Battery-operated fork lift trucks:

If switching troubles are experienced in the electric system, spray the exposed con-
A Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed con-
tacts with contact spray and remove any oxide layer on the contacts of the operating tacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation. controls by repeated operation.
f Perform several brake tests immediately after recommissioning the truck.

f Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward 8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36) incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek- At least once yearly, or after any untoward incident, the fork lift truck has to be chek-
ked by a qualified inspector. The inspector must assess the condition of the truck from ked by a qualified inspector. The inspector must assess the condition of the truck from
a standpoint purely concerned with safety aspects, uninfluenced by any company or a standpoint purely concerned with safety aspects, uninfluenced by any company or
economic circumstances. The inspector must be adequately informed and experi- economic circumstances. The inspector must be adequately informed and experi-
enced to be able to assess the condition of the fork lift truck and the effectiveness of enced to be able to assess the condition of the fork lift truck and the effectiveness of
the safety installations based on the technical rules and principles governing the in- the safety installations based on the technical rules and principles governing the in-
spection of fork lift trucks. spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of The inspection must comprise a comprehensive check of the technical condition of
the fork lift truck with regard to accident prevention aspects. Apart from this, the fork the fork lift truck with regard to accident prevention aspects. Apart from this, the fork
lift truck must be thoroughly inspected for damage possibly caused by incorrect use lift truck must be thoroughly inspected for damage possibly caused by incorrect use
of the fork lift truck. The inspection results must be recorded in an inspection report of the fork lift truck. The inspection results must be recorded in an inspection report
which must be kept available for a period spanning at least the next two inspection which must be kept available for a period spanning at least the next two inspection
intervals. intervals.
The user has to ensure that all defects are eliminated without delay. The user has to ensure that all defects are eliminated without delay.
A The manufacturer has set up a special safety service with specially qualified staff. As
visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed
A The manufacturer has set up a special safety service with specially qualified staff. As
visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed
to it. This plaque indicates in which month of which year the next test will be due. to it. This plaque indicates in which month of which year the next test will be due.
0401.GB
0401.GB
F 12 F 12

Jungheinrich EJC EJC-Z 214 16 Operator Manual

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EJC/EJC-Z 14/16 06.

f Used before safety instructions which must be observed to avoid danger to

Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft

Telephone: +49 (0) 40/6948-0 Telephone: +49 (0) 40/6948-0

B Truck description B Truck description

1 Description of application .................................................................... B 1 1 Description of application .................................................................... B 1

C Transportation and commissioning C Transportation and commissioning

1 Transportation by crane ...................................................................... C 1 1 Transportation by crane ...................................................................... C 1

D Battery - Servicing, recharging, replacement D Battery - Servicing, recharging, replacement

Pos. EJC EJC-Z Description Pos. EJC EJC-Z Description

A Specification of technical data according to VDI 2198. Technical modifications and

Description EJC 14 EJC 16 Description EJC 14 EJC 16

3.2 Dimensions EJC 14/16 3.2 Dimensions EJC 14/16

Description Version1) EJC 14 EJC 16 Description Version1) EJC 14 EJC 16

Description Version1) EJC-Z 14 EJC-Z 16 Description Version1) EJC-Z 14 EJC-Z 16

Continuous sound level: 65 dB(A) Continuous sound level: 65 dB(A)

A The continuous sound level is a value averaged according to standard regulations,

Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)

3.5 Conditions for application 3.5 Conditions for application

Ambient temperature: Ambient temperature:

- during operation 5 °C to 40 °C - during operation 5 °C to 40 °C

Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx

Xxxxx Xxxxxxxxxxxxxxxx Xxxxx Xxxxxxxxxxxxxxxx

Item Description Item Description

Item Designation Item Designation Item Designation Item Designation

4.2 Load capacity 4.2 Load capacity

f The label (18) includes a table indicating

4.4 Label/Order/Inventory/Service No. 4.4 Label/Order/Inventory/Service No.

Item Description Item Description

m Secure the hoisting gear to the hoisting

f This type of operation is prohibited on slopes and inclinations.

f If you reached the target location, reset

m Only batteries with closed tray may be used.

f Battery weight and dimensions have considerable influence on operational safety of

3 Open battery hood 3 Open battery hood

f The battery hood (1) is held in place by its own weight.

f The battery charger must not be opened. If it is damaged, it has to be exchanged.

Mains supply Mains supply

A The recharge procedure is automatically continued after a power failure.

f The mains cable must not be damaged.

Charging times Charging times

Fill-up charge Fill-up charge

– Withdraw the battery connector. – Withdraw the battery connector.

– Withdraw the battery connector. – Withdraw the battery connector.

Mounting the battery: Mounting the battery:

m If maintenance-free batteries are used,

When a remaining battery capacity of When a remaining battery capacity of

When a remaining battery capacity of 16 When a remaining battery capacity of 16

EMERGENCY STOP EMERGENCY STOP

Emergency stop Emergency stop

Driving on slopes Driving on slopes

m The load must be transported pointing towards the mountain!

Shunt driving Shunt driving

m The service brake is only activated after releasing the

A The lifting/lowering speed can be conti-

m Avoid any abrupt lowering of the load unit.

Lifting the wheel arms Lifting the wheel arms

Emergency lowering system Emergency lowering system

A The required Allen key (2.5 mm) can be

The lifting device is lowered. 17 The lifting device is lowered. 17